Reel construction



Feb. 1, 1966 R. F. RANDOLPH REEL CONSTRUCTION Filed March 1s, 196s nited States Patent 3,232,556 REEL CONSTRUCTIN Roland F. Randolph, RR. 2, Danville, Ind. Filed Mar. 18, 1963, Ser. No. 265,668 4 Claims. (Cl. 242-115.631)

The present invention relates to a reel.

Onev type of reel used for transporting insulated and non-insulated wire is that disclosed in my copending application S.N. 210,292, filed July 5, 1962, now Patent No. 3,116,034. This reel uses routs in the inside faces of the flanges for receiving the ends of staves making up the core of the reel. One se-rious problem in the use of such reels is the failure of the reel by separation of the ange center from the flange with subsequent loss of the flange and the wire. Such failures occur as a result of loads acting at an angle on the flanges as a result of droppin-g or other sharp blows on the reel. One solution to this problem is proposed in the above mentioned patent application and is embodied in the structure illustrated in FIGS. 3-5 of that application. In actual practice, this solution has resulted in much greater strength for the reels but has not completely eliminated the problem.

Consequently, one object of the present invention is to provide an improved reel construction which reduces reel failures for the same amount of material in the reel.

Another object of the present invention is to provide a reel highly resistant to failure by reel flanges breaking away from the main body of the reel.

Still another object of the invention is to provide a stronger reel for a lower price and for less weight of material going into the reel. Because the cost of shipping wire depends so heavily on the weight of the reel itelf, any possible reduction of this weight is very desira le.

A further object of the present invention is to provide a reel which is highly resistant to shear failures throughout the reel.

Another object of the present invention is to provide a reel highly resistant to failure from asymmetrical forces exerted on the flanges of the reel, for example, resulting from sliding, tipping or turning of the reel.

Related objects and advantages will become apparent as the description proceeds.

One embodiment of the reel of the present invention comprises a pair of circular llanges each having a coaxial shear plug stapled to one face thereof. There is also provided a core having a cylindrical shape of slightly greater diameter than the shear plug. At the opposite ends of the core which is made up of a plurality of staves, there are formed annular recesses each of which receives a respective shear plug. There is also provided a strap extending through the flanges and shear plugs and through the interior of the core and holding the flanges toward one another and the shear plugs seated in the core recesses.

The full nature of the invention will be understood from the accompanying drawings and the following description and claims.Y

FIG. 1 is a perspective view of a reel constructed according to the present invention.

FIG. 2 isan enlarged section taken perpendicularly to the axis of the reel of FIG. 1 and through the core of the reel.

FIG. 3 isan enlarged section taken along the line 3-3 of FIG. 2 in the direction of the arrows.

FIG. 4 is a fragmentary perspective view of an alternative stave for use in the present invention.

FIG. Sis a section similar to FIG..2 of an alternative embodiment of the invention using the stave construction of FIG. 4.

3,232,556 Patented Feb. l, 1966 ICC For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawing and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope yof the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

Referring now more particularly to the drawings, there is illustrated a reel made up in general of a pair of flanges l@ and a core 11. The flanges 10 are preferably formed of plywood and are provided with the usual dog holes 12 and with a test hole 13 located just adjacent the core 11. The flanges 1@ have a circular configuration and have a circular opening 15 in the center of the ilanges which may be used to receive a rod for use in unreeling. Each of the flanges is also provided with four bores 16 each equally spaced from the axis of the flange for reception of straps 17.

The core 11 is made up of a plurality of staves 2l), the construction of which is described in detail in my above mentioned copending application. Each of the staves 20 is formed from a flat board such as, for example, a 1 x 4. The outer part-cylindrical surface 21 of the staves is formed on one side of the flat board and the radial surfaces 22 are formed on the longitudinal edges of the board. The cylindrical recesses 25 defined by the surfaces 26 and 27 at each end of each stave is then formed by a rotary mill, saw blade, router or similar apparatus. As a result, the staves 2lb include a central portion 30 which has a cross section best shown in FIG. 2 as including a flat surface 31 on the inside of the core 11 and the part-cylindrical surface 21 on the outside of the core. The flat surface 31 and the part-cylindrical surface 21 are joined by surfaces 22 which extend radially of the core.

Thus, when the core 11 is assembled as fragmentarily shown in FIG. 2, the external surface dened by the staves making up the core is a cylinder while the internal surface is a polyhedron. The core 11 further includes cylindrical shear plugs or discs 32 each of which is received in one end of the core and more particularly in engagement with the surfaces 26 and 27 defining the annular recesses 25. The discs 32 are stapled to the individual staves 3l) by staples 35, for example, two such staples being used to staple each stave to the respective disc. In assembling the core 11, it is the usual practice to secure all of the staves but one in the manner illustrated in FIG. 3. After the flanges 1l) have been secured in place as shown in FIG. l, the final stave 20 is secured in place by radially projecting staples 36 in the manner illustrated in FIG. 2.

After the -core 11 has been assembled, the flanges 1li are secured to the core and more particularly to the discs 32 by staples 37. Finally, the straps 17 are passed through the apertures 16 and through registering apertures in the discs 32 and also through the interior of the core 11. The opposite ends of the straps are then brought together as illustrated in FIG. 1. After placing tension on the straps, the ends are clamped together by means of suitable cornmercially available clinching devices 4d in order to hold the flanges toward one another and to maintain the reel in assembled condition. It should be mentioned that the various staples 35, 36 and 37 are highly resistant to shear between the various members which they secure together. The straps 17, on the other hand, provide only a tension force which results in a compression force of the flange against the discs and against the ends 41 of the staves.

By the combined action of the straps 17 and the staples, an extremely strong yet light weight reel is produced.

An alternative embodiment of the invention is illustrated in FIGS. 4 and 5 and is identical to the embodiment of FlGS. l-3 With the following exceptions. The staves 50 are formed from 2 x 45 and instead of the cylindrical recess of the core 1l, each of the staves Sil has a straight recess S. When the staves Su are assembled to form the core 52, the straight recesses Si define a generally annular recess of polygonal shape. Thus, the shear plug 55 has a polygonal rather than a circular shape so that it properly fits the recess defined by the individual recesses 5l. Also, Where stronger, more Wearresistant wire is involved, it may not be necessary to completely round ofiC the external surface 56 of each of the staven and instead, the corners S7 of each stave are rounded offl producing the stave configuration illustrated in FIGS. 4 and 5. In all other respects, With the exception of size, the embodiment of FIGS. 4 and 5 is identical to the embodiment of FlGS. 1 3.

From the above description, it Will be evident that the present invention provides an improved reel construction Which reduces reel failures resulting from shear or resulting from asymmetrical forces exerted on the flanges of the reel. lt has also been found that the present invention provides a reel which is highly resistant to failure by reel flanges breaking away from the main body of the reel. Furthermore, the reel of the present invention has been found to provide a stronger reel for a lower price and for less Weight of material going into the reel.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come Within the spirit of the invention and the scope of the claims are also desired to be protected.

v The invention claimed is:

l. A reel comprising a plurality of staves assembled to form a cylindrical core, said core having a pair of oppositely projecting end portions and a pair of annular recesses formed inside of said end portions at the opposite ends of the core, a pair of plugs each received Within one of said recesses, first staples securing each plug to each of said staves, said staples extending axially of said core through said plugs and into said staves, a pair of end flanges of larger diameter than said plugs, second staples securing each of said end flanges to a respective one of said plugs, said second staples extending axially of said core through said end langes into said plugs, and a pair of straps extending through the flanges and the interior of said core and holding said flanges toward one another and said plugs seated in said recesses and also holding all of the staple connected members in rm engagement with one another at the staple connections.

2. A reel comprising a plurality of staves assembled to form a hollovir core, each of said staves including a central portion joining a pair of opposite end portions, each central portion having a cross section which is curved at the outside of said core and has a flat surface on the inside of said core, each central portion further including sides joining said part-circular surface and said flat surface, said sides extending radially of said core, each central portion further including shoulders joining the staves flat surface and opposite end portions, said shoulders extending radially and with said end portions defining a pair of annular recesses at the opposite ends of the core, a pair of shear plugs each received Within one of said recesses, first staples securing each plug to each of said staves, said staples extending axially of said core through said plugs and shoulders into said central portions, a pair of end flanges of larger diameter than said plugs, second staples securing each of said end flanges to a respective one of said plugs, said second staples extending axially of said casse core through said end flanges into said plugs, and a pair of lstraps extending through the flanges and the interior of said core and holding said flanges toward one another and said plugs seated in said recesses and also holding all of the staple connected members in firm engagement with one another at the staple connections.

3. A reel comprising a plurality of staves assembled to form a cylindrical core, each of said staves including a central portion joining a pair of opposite end portions, each central portion having a cross section which is curved to*r a part-circular surface at the outside of said core and has a flat surface on the inside of said core, each central portion further including sides joining said partcircular surface and saidiilat surface, said sides extending radially of said core, each central portion further including shoulders joining the staves flat surface and opposite end portions, said shoulders extending radially and with said end portions defining a pair ofannular recesses at the opposite ends of the core, a pair of circular discs each received Within one of said recesses, first staples securing each dis-e to each of said staves, said sta-ples extending axially of said core through said plugs and shoulders into said central portions, a pair of end flanges of larger diameter than said discs, second staples securing each of said end flanges to a respective one of said disc, said second staples extending axially of said core through said end flanges into said discs, and a pair of straps extending through the flanges and the interior of said core and holding said flanges toward one another and said discs seated in said recesses and also holding all of the staple connected members in firm engagement with one another at the staple connections.

4. A reel comprising a plurality of staves assembled to form a generally cylindrical core, each of said staves including a central portion joining a` pair of opposite end portions, each central portionhaving a cross section which is curved to a rounded off surface at the outside of said core and has a flat surface on the inside of sai-d core, each central portion further including sides joining said partcircular surface and said flat surface, said sides extending radially of said core, each central portion further including shoulders joining the staves flat surfaceand opposite end portions, each of said shoulders and contiguous end portion defining a straight groove of right-angled cross section, said shoulders extending radially and with said end portions defining a pair of annular polygonal recesses at the opposite ends of the core, a pair of polygonal shear plugs each received Within one of said recesses, first staples securing each plug to each of said staves, said staples extending axially of said core through said plugs and shoulders into said central portions, a pair of end flanges of larger diameter than said plugs, secondv staples securing each of said end flanges to a respective one of said plugs, said second staples extending axially of said core through said end flanges into said plugs, and a pair of straps extending through the flanges and the interior of said core and holding said flanges toward one another and said plugs seated in said recesses and also holding all of thestaple connectedmembers in firm engagement With one another at the staple connections.

References Cited b y therExaminer UNITED STATES PATENTS 343,943 9/1886 Young 242-118.61` 1,478,805 12/1923 Tutu@ 242- 1136 1,354,384 4/1932 scm/n1 242 11s,61 2,148,394 2/1939 Thornton 24a-118.6` 2,499,268. 2/1950 Crooks 242 118.6 3,116,034 12/1963 Randolph 242-118.61.

ronErGN PATENTS 261,189 ll/l926; Great Britain. 288,397 1 /1928 Great Britain;

MERVlN STEN, Primary Examiner. 

1. A REEL COMPRISING A PLURALITY OF STAVES ASSEMBLED TO FORM A CYLINDRICAL CORE, SAID CORE HAVING A PAIR OF OPPOSITELY PROJECTING END PORTIONS AND A PAIR OF ANNULAR RECESSES FORMED INSIDE OF SAID END PORTIONS AT THE OPPOSITE ENDS OF THE CORE, A PAIR OF PLUGS EACH RECEIVED WITHIN ONE OF SAID RECESSES, FIRST STAPLES SECURING EACH PLUG TO EACH OF SAID STAVES, SAID STAPLES EXTENDING AXIALLY OF SAID CORE THROUGH SAID PLUGS AND INTO SAID STAVES, A PAIR OF END FLANGES OF LARGER DIAMETER THAN SAID PLUGS, SECOND STAPLES SECURING EACH OF SAID END FLANGES TO A RESPECTIVE ONE OF SAID PLUGS, SAID SECOND STAPLES EXTENDING AXIALLY OF SAID CORE THROUGH SAID END FLANGES INTO SAID PLUGS, AND A PAIR 